Replacement card packaging

ABSTRACT

A package for distributing a presentation instrument includes a shipping indicator comprising a shipping destination address and an envelope that has a first substantially clear window and contains the presentation instrument and the shipping indicator. The shipping destination address is visible through the first substantially clear window. The package also includes a shipping container that has a second substantially clear window and contains the envelope. The shipping destination address is visible through the second substantially clear window. A method for assembling a package for a presentation instrument includes providing the presentation instrument, a shipping indicator, an envelope, and a shipping container. The presentation instrument and the shipping indicator are inserted into the envelope and the envelope is inserted into the shipping container. The shipping destination address is visible through the first and second substantially clear windows.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to application Ser. No. ______ (attorneydocket number 020375-087800US), entitled “Emergency card replacement”and, application Ser. No. ______ (attorney docket number020375-088000US), entitled “System and method for preparing cardreplacement”, all three applications being filed on the same day andhaving a common assignee.

BACKGROUND OF THE INVENTION

Credit cards, debit cards, and other kinds of presentation instrumentshave become a very popular means of making purchases. In a typicalcredit card transaction, a consumer presents the card at the time of apurchase. Account information is read from the card and the transactiondetails are transmitted to the card issuer, who has extended credit tothe consumer. Upon approval, the purchase is completed, the issuer paysthe merchant for the purchase, and the consumer is billed by the issuerfor the purchase during the next regular billing cycle. A typical debitcard transaction proceeds similarly at the point of sale, but payment ismade from funds in an account associated with the debit card, ratherthan by the issuer. Both consumers and merchants benefit from the speedand convenience of transactions made with these kinds of presentationinstruments.

Consumers also may find that such instruments are more secure thanpaying with cash. Many transactions require the person presenting thecard to be authenticated as the rightful account holder, making itdifficult for the card to be used fraudulently. Furthermore, thecardholder's liability for fraudulent charges may be limited by law.These kinds of presentation instruments are especially convenient foruse when the cardholder is traveling. The cardholder need not riskcarrying large amounts of cash, and currency conversions are handledautomatically by the systems administering the accounts.

Because of these beneficial aspects, consumers may become dependent ontheir cards, especially when traveling. If a card is lost or stolen, thecardholder may be left without other means for making purchases. Eventhough the risk of liability for any fraudulent charges may be small,the inconvenience of a lost card may be enormous. Some card issuersrecognize this problem, and provide emergency card replacements. Someadvertise their card replacement speed and convenience as a way todifferentiate their cards from those of other issuers.

There is accordingly a need to provide replacement presentationinstruments quickly, accurately, and at low cost.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, a package for distributing a presentation instrumentcomprises shipping indicator comprising a shipping destination address,and an envelope comprising a first substantially clear window andcontaining the presentation instrument and the shipping indicator. Theshipping destination address is visible through the first substantiallyclear window. The package further comprises a shipping containercomprising a second substantially clear window and containing theenvelope, and the shipping address is visible through the secondsubstantially clear window.

In some embodiments, the presentation instrument is affixed to theshipping indicator. In some embodiments, the shipping indicatorcomprises a tri-fold carrier made of paper. In some embodiments, theenvelope is the size of a number ten business envelope. In someembodiments, the shipping container is substantially flat and measuresapproximately 9 by 12 inches in width and length. In some embodiments,the package further comprises means for constraining movement of theenvelope within the shipping container such that the shippingdestination address and tracking indicium remain visible through thesecond substantially clear window. In some embodiments, the means forconstraining the movement of the envelope comprises a bead of adhesivejoining front and back walls of the shipping container. In someembodiments, the bead of adhesive is continuous. In some embodiments,the shipping information further comprises a tracking indicium, and thetracking indicium is visible through the first and second substantiallyclear windows.

In another embodiment, a method for assembling a package for apresentation instrument comprises providing the presentation instrument,providing a shipping indicator that comprises shipping destinationaddress, providing an envelope comprising a first substantially clearwindow, and providing a shipping container comprising a secondsubstantially clear window. The presentation instrument and the shippingindicator are inserted into the envelope such that the shippingdestination address is visible through the first substantially clearwindow, and the envelope is inserted into the shipping container suchthat the shipping destination address is visible through the secondsubstantially clear window.

In some embodiments, the shipping information further comprises atracking indicium that is visible through the first and secondsubstantially clear windows when the envelope has been inserted into theshipping container. In some embodiments, the method further comprisesobtaining the tracking indicium from a shipper. In some embodiments, thetracking indicium comprises a tracking number. In some embodiments, thetracking indicium comprises a bar code. In some embodiments, the methodfurther comprises printing the shipping destination address on theshipping indicator. In some embodiments, the shipping indicator is afolded carrier made of paper. In some embodiments, the presentationinstrument is a card comprising a magnetic strip. In some embodiments,the method further comprises affixing the presentation instrument to theshipping indicator. In some embodiments, the method further comprisesprinting account information on the shipping indicator, the accountinformation relating to the presentation instrument. In someembodiments, the method further comprises constraining the envelopewithin the shipping container such that the shipping destination addressremains visible through the second substantially clear window. In someembodiments, the method further comprises personalizing the presentationinstrument with a first set of account information, printing a secondset of account information on the shipping indicator, and associatingthe presentation instrument and the shipping indicator. In someembodiments, the presentation instrument is hidden from view.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a process and system for distributing a presentationinstrument, in accordance with an example embodiment of the invention.

FIG. 2 shows a shipping indicator, in accordance with an exampleembodiment of the invention.

FIG. 3 shows an envelope comprising a clear window, in accordance withan example embodiment of the invention.

FIG. 4 shows a shipping container, in accordance with an exampleembodiment of the invention.

FIG. 5 depicts a top view of a system for assembling a shipping package,in accordance with an example embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Most households in the United States now hold at least one credit card,and millions of new cards are issued annually. In order to meet thisdemand, highly-automated systems and processes have been developed formanufacturing and distributing new cards rapidly and in largequantities. New cards are typically distributed to consumers throughfirst class mail or similar channels. This kind of mail often takesseveral days to reach its destination, and is often presented inpre-sorted high-volume mailings in order to reduce the cost to thesender.

Relatively few cards require emergency replacement, and it is notpossible to predict which cards will need replacement. The mail channelsused for new cards are therefore inappropriate for emergency replacementcards. Replacement cards are preferably shipped by overnight courier.Previous emergency replacement procedures have required significantmanual processing, including the manual association of cards, cardcarriers, and shipping labels produced and printed separately. Thisextensive manual processing is expensive and prone to error.

Embodiments of the present invention provide automated systems andmethods for providing emergency replacements for credit cards, debitcards, and other presentation instruments.

FIG. 1 illustrates a process 100 for distributing a presentationinstrument, in accordance with an example embodiment of the invention.The illustrated process is especially suited to providing emergencyreplacement presentation instruments. For example, when a card or otherpresentation instrument is lost or stolen, the cardholder may call theissuer and speak to a customer service representative, who then arrangesfor the card replacement. The customer service representative mayrequest information from the cardholder, such as the cardholder's name,a location to which to ship the replacement card, and other data. Theinformation is entered into a computer system and a card replacementrequest initiated.

In the process of FIG. 1, a presentation instrument issuer 101communicates over a communication link 115 to a controller 102 that apresentation instrument is to be produced and sent. Controller 102 maybe, for example, a general-purpose computer system executing a programstored on a computer-readable medium. The computer may be, for example,a “System i” computer available from International Business MachinesCorp., of Armonk, N.Y., USA, or may be another suitable computer system.While controller 102 is shown as a single block in FIG. 1, one of skillin the art will recognize that controller 102 may be a single computeror may comprise a plurality of interconnected computers, which may beco-located or widely separated. Process 100 may be performed by a singleentity, for example issuer 101, or the various parts of the process maybe performed by two or more different entities. For example, issuer 101may outsource the production and distribution of presentationinstruments to a processing organization that is a business entityseparate from issuer 101. Alternatively, issuer 101 may outsource theentire process of issuing presentation instruments to the processingentity. Many other arrangements are also possible.

The communication from issuer 101 to controller 102 may include accountand customer information to be used in producing and distributing thepresentation instrument. For example, the communication may indicate thename of the customer to whom the presentation instrument will be issued,a shipping destination address to which the presentation instrument willbe shipped, and an account number that will be assigned to thepresentation instrument. Alternatively, controller 102 may have apre-assigned list of account numbers to be used for presentationinstruments distributed by process 100, in which case the communicationfrom issuer 101 need not contain an account number.

Controller 102 sends the account information to a personalizationmachine 103, which produces a unique presentation instrument 104.Personalization refers to the process of making each presentationinstrument unique by recording account information on the presentationinstrument. In one example process, the presentation instruments areplastic cards, each comprising a magnetic strip on which information maybe recorded magnetically. Until the cards are personalized, they do notcontain any account or customer name information. During personalizationof a card having a magnetic strip, the account number, customer name,expiration date, and other information may be recorded on the card byembossing the information onto the plastic card, and may also berecorded magnetically on the magnetic strip. During personalization of asmart card or a radio-frequency enabled payment device, accountinformation may be recorded electronically in a memory on thepresentation instrument. Personalization machine 103 may be, forexample, a Maxsys, MX6000, or model 9000 machine available from DatacardCorporation, of Minnetonka, Minn., USA, or an other suitablepersonalization machine. After personalization, each card is uniquelyidentifiable and is associated with a particular account at the issuerof the card. In the example of FIG. 1, the presentation instrumentproduced is a card of this type, but one of skill in the art willrecognize that other kinds of devices may be used as presentationinstruments, and that the process may be used with may kinds of devices.For example, other kinds of devices that may be used as presentationinstruments include chip-based cards, smart cards, and radio-frequencyenabled devices such as key fobs, cards, watches, or other devices.

Controller 102 also communicates with a shipper 105 over a communicationlink 112. Shipper 105 may be, for example, a company that providesovernight courier service. Controller 102 may provide to shipper 105information such as where a presentation instrument will be shipped fromand the shipping destination. Shipper 105 may provide to controller 102a tracking number and other identifying information for a particularpackage.

Controller 102 then communicates with a printer 106, which is configuredto print a shipping indicator 107. Printer 106 may be, for example, alaser printer, an inkjet printer, or another kind of printer. In theexample of FIG. 1, shipping indicator 107 is a tri-fold carrier made ofpaper, but other arrangements are possible. For example, shippingindicator 107 may simply be a card or other insert. Shipping indicator107 comprises the information normally found on a shipping label. Forexample, shipping indicator 107 may comprise a shipping destinationaddress and a tracking indicium such as a tracking number, bar code orother unique identifier for the eventual package in which presentationinstrument 104 will be shipped. Shipping indicator 107 may also compriseaccount information relating to presentation instrument 104, of the kindoften found on a carrier with which a presentation instrument is shippedor mailed. The set of accounting information printed on shippingindicator 107 may but need not be the same as the set of accountinformation included on presentation instrument 104. For example, someinformation stored on presentation instrument 104 may be omitted fromthe set of account information printed on shipping indicator 107.

Preferably, but not necessarily, presentation instrument 104 is affixedto shipping indicator 107, forming a unit 108. For example, presentationinstrument 104 may be attached to shipping indicator 107 using anadhesive that is secure yet leaves presentation instrument 104 readilyremovable from shipping indicator 107. Or corners of presentationinstrument 104 may be tucked into cutouts or slots cut into shippingindicator 107. Preferably, personalization machine 103 and printer 106are in close proximity, so that presentation instrument 104 and shippingindicator 107 can be associated with each other relatively early in theprocess, in order to avoid errors that may occur of presentationinstrument 104 and shipping indicator 107 become separated from eachother. A unit such as unit 108 contains all of the account and shippinginformation necessary to provide a replacement presentation instrument.A more detailed view of one example shipping indicator 107 is shown inFIG. 2.

Presentation instrument 104 and shipping indicator 107 (which may beassociated into a unit 108) are inserted, using a first automatedinserter 113, into an envelope 109. Envelope 109 comprises asubstantially clear window of sufficient size that the shippinginformation printed on shipping indicator 107 is visible when shippingindicator 107 and presentation instrument 104 are inserted into envelope109. In one example embodiment, envelope 109 is a number ten envelopeapproximately 4.125 by 9.5 inches, and the clear window is approximately3.125 by 8.5 inches, covering approximately 67 percent of the frontalarea of envelope 109. Of course, other dimensions may be used, so longas the shipping information printed on shipping indicator 107 remainsvisible through the clear window. The clear window is preferably coveredby a substantially clear plastic sheet adhered to the inside of envelope109. A more detailed view of one example envelope 109 is shown in FIG.3. Preferably, presentation instrument is hidden by shipping indicator107, and is not visible through the substantially clear window afterinsertion into envelope 109.

Envelope 109, containing shipping indicator 107 and presentationinstrument 104, is then inserted, using a second automated inserter 114,into a shipping container 110, forming package 111. Shipping container110 comprises a second substantially clear window of sufficient sizethat, when envelope 109 is inserted into container 110, the shippinginformation printed on shipping indicator 107 is visible through boththe first clear window in envelope 109 and the second clear window incontainer 110. In some embodiments, a bead of adhesive is placed betweenthe front and back faces of shipping container 110, dividing theinterior of container 110 and constraining the movement of envelope 109inside shipping container 110 so that clear windows in envelope 109 andcontainer 110 remain aligned and the shipping information remainsvisible through both. The bead of adhesive may be continuous or may beinterrupted, comprising a plurality of shorter beads or spots ofadhesive. Other means may be used for constraining the movement ofenvelope 109 inside shipping container 110. For example, the front andback of shipping container 110 may be joined, either continuously orintermittently, along a line by stapling, sewing, heat welding, or byany other suitable means. A more detailed view of an example shippingcontainer 110 is shown in FIG. 4.

Shipping container 110 may then be automatically sealed, and package 111shipped to the shipping destination address using shipper 105. Theprocess of FIG. 1 has several advantages over prior card replacementprocesses. The unique presentation instrument packaging, wherein theshipping information is printed on shipping indicator 107 and showsthrough the clear windows in envelope 109 and shipping container 110,avoids a separately-printed mailing label, and thus reduces the numberof packaging steps and reduces the complexity of the replacementprocess. Shipping indicator 107 may be a component for which automaticinsertion equipment is already available, and therefore the packagingarrangement enables automation of the card replacement process.Opportunities for errors are also reduced because fewer components mustbe associated into a card replacement package. Only presentationinstrument 104 and shipping indicator 107 need to be particularlyassociated, and once they are properly associated, shipment of thecorrect card to the correct destination is assured. Because all of theshipping information is printed on shipping indicator 107 and noshipping information is printed or labeled on envelope 109 or shippingcontainer 110, no particular envelope or shipping container need beselected or tracked.

FIG. 2 shows a more detailed view of a shipping indicator 107, inaccordance with an example embodiment of the invention. In this example,shipping indicator 107 is a tri-fold carrier having a top section 201,middle section 202, and bottom section 203. In an unfolded state,shipping indicator 107 may be, for example, approximately 8.5 by 11inches, although other sizes may be used. Top section 201 is printedwith various information relating to the shipping of the eventualpackage in which shipping indicator 107 will be placed. For example,addresses 204 and 205 indicate the address from which the package is tobe shipped, and the destination address respectively. In this example,top section 201 is also printed with one or more tracking indicia. Inthe example of FIG. 2, either or both of a tracking number 206 and a barcode 207 may be used for tracking purposes. Other information may beprinted on top section 201 as well. Presentation instrument 104 has beenattached to middle section 202. Various account information 208 may beprinted on shipping indicator 107, for example on middle section 202,and information may be printed on bottom section 203 as needed ordesired.

FIG. 3 shows a more detailed view of an envelope 109, in accordance withan example embodiment of the invention. In this example, envelope 109 isa number ten business envelope, approximately 4.125 by 9.5 inches andsuitable for holding a standard 8.5 by 11 inch sheet folded in threesections. Any other suitable size envelope may be used. Envelope 109comprises a front face having a substantially clear window 301. Clearwindow 301 may be formed by removing part of the opaque front section ofenvelope 109 and adhering a plastic, cellophane, or other substantiallyclear sheet to the inside of envelope 109 to cover the opening.Alternatively, window 301 may simply be an opening in envelope 109,without a covering sheet. In this example, clear window 301 extends towithin about one half inch of each edge of envelope 109, leaving roomfor information printed on shipping indicator 107 to be visible whenshipping indicator 107 is inserted into envelope 109.

FIG. 4 shows a more detailed view of a shipping container 110, inaccordance with an example embodiment of the invention. Shippingcontainer 110 is preferably a shipping envelope measuring approximately9 by 12 inches, and made of cardboard, heavy paper, or another suitablematerial. Other sizes may be used as well. Shipping container 110 may bedurable and semi-rigid, and of the kind commonly used for overnight orexpress shipment of documents. Shipping container 110 comprises asubstantially clear window 401, formed in a manner similar to the waywindow 301 in envelope 109 is formed. A portion of the front ofcontainer 110 may be removed, and a substantially clear sheet adhered tothe inside surface of container 110 covering the opening. Alternatively,window 401 may simply be an opening in shipping container 110, without acovering sheet. Preferably, window 401 in container 110 is at least aslarge as window 301 in envelope 109, and may be conveniently madesomewhat larger. In some embodiments, a bead of adhesive 402 is placedbetween the front and back walls of container 110, so that the front andback are adhered together. This divides the interior of shippingcontainer 110 into upper and lower sections 403 and 404 respectively.When envelope 109 is placed in upper section 403, adhesive 402constrains the movement of envelope 109 such that window 301 in envelope109, and consequently the shipping information printed on shippingindicator 107 and showing through window 301, remains showing throughwindow 401.

While envelope 109 and container 110 may be specially made to comprisethe aligning clear windows 301 and 401, they need not be printed orlabeled in any way. All of the required information for shipping package111 is printed on shipping indicator 107 and associated withpresentation instrument 104 early in the process. No additional labelsneed be printed, associated with other items, or manually affixed to ashipping package. As such, the assembly of package 111 may be automated,and errors may be avoided.

FIG. 5 depicts a top view of a system 500 for assembling a shippingpackage, in accordance with an example embodiment of the invention.System 500 is preferably controlled by a control system 511, which maybe a microprocessor system, computer, programmable logic controller,dedicated logic, or other suitable control system. Control system 511synchronizes the various components of system 500, and may perform otherfunctions such as error detection, counting, or other tasks.

In the example embodiment shown in FIG. 5, a feeder 501 feeds anenvelope 109 from a supply of envelopes. The envelope contains areplacement presentation instrument and a shipping indicator. Theshipping indicator comprises a shipping destination address visiblethrough a first clear window in the envelope 109, and may also comprisea tracking indicium visible through the clear window. In FIG. 5,envelope 109 is positioned with the clear window downward, so that thewindow is not visible in the drawing. For the purposes of thisdisclosure, the shipping destination address and tracking indicium areconsidered to be visible through the first clear window even if theenvelope 109 must be removed from system 500 in order for the window tobe seen.

Feeder 501 may be one of a variety of envelope feeders known in the art,and in some embodiments may be a stream feeder. A stream feeder is onethat moves sheets or envelopes in an overlapping flow, rather thanmoving them with space between.

System 500 also comprises a supply 502 of shipping containers, of whichshipping container 110 is an example. Each shipping container comprisesa second clear window. The shipping containers in FIG. 5 are positionedwith their clear windows downward, so the clear windows are not visiblein the drawing.

System 500 also comprises a first transport mechanism 503 thattransports shipping containers from the supply 502 of shippingcontainers, and places each in position for the feeder to insert anenvelope into it. Each envelope is inserted such that once the envelopeis inside the shipping container, the shipping destination address andany tracking indicium are visible through the clear window in theshipping container. Preferably, first transport mechanism 503 comprisesan intermittently-moving feed belt 504 that draws shipping containersfrom the supply 502 of containers. The motion of feed belt 504 may bestarted and stopped by a clutch and brake system. In some embodiments, aset of vacuum cups 512 operate to hold open shipping container 110during insertion of envelope 109.

System 500 further comprises a second transport mechanism 505 thataccepts the filled shipping containers from the first transportmechanism and passes each received container through a sealingmechanism. Preferably, second transport mechanism 505 comprises acontinuously-moving feed belt 506. Once a shipping container hasreceived an envelope, no further coordination with other feed streams isnecessary, and the shipping container can be safely moved by acontinuously-moving transport mechanism. In the example of FIG. 5, eachshipping container, including shipping container 110, is a substantiallyflat shipping envelope, which may be made of heavy paper, cardboard, oranother suitable material. Each example container comprises a flap 507,which may further comprise an adhesive covered by a liner 508. Liner 508may be, for example, a glossy paper or plastic film designed to adhereonly lightly to the pre-positioned adhesive, and to protect the adhesivefrom accidental contact with other items.

During transport of the shipping containers by one or both of first andsecond transport mechanisms 503 and 505, a rotating brush 509 may removethe liner from the adhesive of each container, in preparation forsealing of the container. In the example of FIG. 5, sealing isaccomplished by a set of rollers and shaped guides 510 that fold eachflap 507 over onto the main body of the container as the transportmechanisms drive the container through the rollers and shaped guides510. After sealing, the filled shipping containers may be collected inan output hopper or bin, and then given to a representative of shipper105 for shipping.

The invention has now been described in detail for the purposes ofclarity and understanding. However, those skilled in the art willappreciate that certain changes and modifications may be practicedwithin the scope of the appended claims.

1. A package for distributing a presentation instrument, the package comprising: a shipping indicator comprising a shipping destination address; an envelope comprising a first substantially clear window and containing the presentation instrument and the shipping indicator, wherein the shipping destination address is visible through the first substantially clear window; and a shipping container comprising a second substantially clear window and containing the envelope, wherein the shipping destination address is visible through the second substantially clear window.
 2. The package of claim 1, wherein the presentation instrument is affixed to the shipping indicator.
 3. The package of claim 1, wherein the shipping indicator comprises a tri-fold carrier made of paper.
 4. The package of claim 1, wherein the envelope is the size of a number ten business envelope.
 5. The package of claim 1, wherein the shipping container is substantially flat and measures approximately 9 by 12 inches in width and length.
 6. The package of claim 1, further comprising means for constraining movement of the envelope within the shipping container such that the shipping destination address and tracking indicium remain visible through the second substantially clear window.
 7. The package of claim 6, wherein the means for constraining the movement of the envelope comprises a bead of adhesive joining front and back walls of the shipping container.
 8. The package of claim 7, wherein the bead of adhesive is continuous.
 9. The package of claim 1, wherein the shipping information further comprises a tracking indicium, and wherein the tracking indicium is visible through the first and second substantially clear windows.
 10. A method for assembling a package for a presentation instrument, the method comprising: providing the presentation instrument; providing a shipping indicator, the shipping indicator comprising a shipping destination address; providing an envelope comprising a first substantially clear window; providing a shipping container comprising a second substantially clear window; inserting the presentation instrument and the shipping indicator into the envelope such that the shipping destination address is visible through the first substantially clear window; and inserting the envelope into the shipping container such that the shipping destination address is visible through the second substantially clear window.
 11. The method of claim 10, wherein the shipping information further comprises a tracking indicium that is visible through the first and second substantially clear windows when the envelope has been inserted into the shipping container.
 12. The method of claim 11, further comprising obtaining the tracking indicium from a shipper.
 13. The method of claim 11, wherein the tracking indicium comprises a tracking number.
 14. The method of claim 11, wherein the tracking indicium comprises a bar code.
 15. The method of claim 10, further comprising printing the shipping destination address on the shipping indicator.
 16. The method of claim 10, wherein the shipping indicator is a folded carrier made of paper.
 17. The method of claim 10, wherein the presentation instrument is a card comprising a magnetic strip.
 18. The method of claim 10, further comprising affixing the presentation instrument to the shipping indicator.
 19. The method of claim 10, further comprising printing account information on the shipping indicator, the account information relating to the presentation instrument.
 20. The method of claim 10, further comprising constraining the envelope within the shipping container such that the shipping destination address remains visible through the second substantially clear window.
 21. The method of claim 10, further comprising: personalizing the presentation instrument with a first set of account information; printing a second set of account information on the shipping indicator; and associating the presentation instrument and the shipping indicator.
 22. The method of claim 10, wherein the presentation instrument is hidden from view. 